Textured surfaces

ABSTRACT

One embodiment of a method of manufacturing a textured surface may include providing a first thermally stable sheet, printing a pattern of material on the first sheet to form a three-dimensional textured surface, and curing the material, then using said first sheet to impart negative texture into Tedlar faced epoxy composite blanket, which is in turn used to impart texture into a decorative laminate.

CROSS-REFERENCED TO RELATED APPLICATIONS

This application is a continuation of application U.S. Ser. No.11/861,105, filed Sep. 25, 2007, status allowed.

BACKGROUND INFORMATION

1. Field

This invention relates generally to textured surfaces. Moreparticularly, the invention relates to methods for manufacturingtextured surfaces.

2. Background

Many methods exist for manufacturing textured surfaces. One such methodutilizes fabricating and/or purchasing steel plates with the desiredpattern or texture, and then producing the part using the steel plateshaving the desired texture. However, this may be costly, time-consuming,inefficient, complex, may limit custom textures, and/or may lead to oneor more other types of problems.

A method of manufacturing a textured surface is needed to decrease oneor more problems associated with one or more of the existing methods ofmanufacture.

SUMMARY

In one aspect of the disclosure, a method of manufacturing a texturedsurface is disclosed. In one step, a first thermally stable sheet isprovided. In another step, a pattern of material is printed on the firstsheet to form a three-dimensional textured surface on the first sheet.In still another step, the material is cured.

In another aspect of the disclosure, a thermally stable first sheet isprovided having a three-dimensional textured surface on the first sheet.The three-dimensional textured surface was formed by printing a patternof material on the first sheet and curing the material.

These and other features, aspects and advantages of the disclosure willbecome better understood with reference to the following drawings,description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a flowchart of one embodiment of a method of manufacturinga textured surface;

FIG. 2 shows a top-view of one embodiment of a target texture which maybe used in the method of the embodiment of FIG. 1;

FIG. 3 shows a side-view of the target texture of the embodiment of FIG.2;

FIG. 4 shows a top-view of one embodiment of a digital image of thetarget texture of the embodiment of FIG. 2;

FIG. 5 shows a block chart of equipment which may be used to implementthe method of the embodiment of FIG. 1;

FIG. 6 shows a side-view of a first thermally stable sheet which may beused in the method of the embodiment of FIG. 1;

FIG. 7 shows a side-view of the first sheet of the embodiment of FIG. 6after a pattern of material has been printed on the first sheet;

FIG. 8 shows a side-view of the textured surface of the first sheet ofthe embodiment of FIG. 7 being heated and pressed against a Tedlarrelease sheet adhered to an uncured epoxy impregnated fiberglass sheet;

FIG. 9 shows a side-view of a negative three-dimensional texturedsurface of a cured fiberglass composite blanket being heated and pressedinto a decorative laminate to form a three-dimensional textured surfaceon the decorative laminate;

FIG. 10 is a flow diagram of aircraft production and servicemethodology; and

FIG. 11 is a block diagram of an aircraft.

DETAILED DESCRIPTION

The following detailed description is of the best currently contemplatedmodes of carrying out the disclosure. The description is not to be takenin a limiting sense, but is made merely for the purpose of illustratingthe general principles of the disclosure, since the scope of thedisclosure is best defined by the appended claims.

FIG. 1 shows a flowchart of one embodiment of a method 10 ofmanufacturing a textured surface. In one step 12 of the method 10, atarget texture 14, of which a top-view is shown in FIG. 2 and of which aside-view is shown in FIG. 3, may be identified and/or designed. Thetarget texture 14 may comprise a three-dimensional textured pattern 16with some areas 18 of the pattern 16 protruding in direction 20 morethan other areas 22 of the pattern 16 in order to provide a varyingtextured pattern 16. In other embodiments, the target texture 14 andthree-dimensional textured pattern 16 may comprise varying textures ofdiffering uniformity or non-uniformity, differing shapes, differingconfigurations, differing sizes, differing orientations, or protrusionsextending in differing planar or non-planar directions.

In another step 24 of the method 10, a digital image 26, of which atop-view is shown in FIG. 4, may be formed of the target texture 14.FIG. 5 shows a block chart of equipment 27 which may be used toimplement the method 10 of FIG. 1. As shown, a computer 28 may be usedduring step 24 of the method 10 to form the digital image 26. Thedigital image 26 may comprise scanning the target texture 14 into thecomputer 28 using a scanner 30. In another embodiment, a computerprogram 32 on the computer 28 may be used to prepare the digital image26. In still other embodiments, varying equipment and mechanisms may beused to prepare the digital image 26.

In another step 34 of the method 10, a first thermally stable sheet 36,of which a side-view is shown in FIG. 6, may be provided. The firstthermally stable sheet 36 may comprise a flexible film 37 made of Mylaror Polyester. In other embodiments, the sheet 36 may comprise varyingmaterials, including non-flexible materials.

In another step 38 of the method 10, a pattern 40 of material 42 may beprinted on the first sheet 36 to form a three-dimensional texturedsurface 44 on the first sheet 36, as shown in FIG. 7, which is aside-view of the sheet 36 of FIG. 6 after the pattern 40 has beenprinted. The three-dimensional textured surface 44 on the first sheet 36may be formed by printing multiple layers 43 of material 42 on the firstsheet 36 with varying amounts of material 42 being printed in differingareas 45 and 47 of the first sheet 36. In another embodiment, only onelayer of material 42 may be printed on the first sheet 36. As shown inFIG. 5, a printer 46 connected to computer 28 may be used to print 49the pattern 40 of material 42 on the first sheet 36.

The three-dimensional textured surface 44 printed on the first sheet 36may be substantially identical to the target texture 14 inputted intothe digital image 26. For instance, some areas 48 of the pattern 40 mayprotrude in direction 50 in the same amount and direction as areas 18 ofthe pattern 16 protruding in direction 20 as shown in FIGS. 2 and 3.Similarly, other areas 52 of the pattern 40 may protrude in direction 50in the same amount and direction as areas 22 of the pattern 16protruding in direction 20 as shown in FIGS. 2 and 3. In such manner, avarying textured surface 44 may be formed on the first sheet 36. Inother embodiments, the three-dimensional textured surface 44 may have apattern 40 of material 42 in any shape, size, orientation,configuration, uniformity, non-uniformity, or direction. The material 42used to form the three-dimension textured surface 44 on the first sheet36 may comprise an ink such as an Ultra Violet Cured ink. In otherembodiments, the material 42 may be varied.

In another step 54 of the method 10, the material 42 printed on thefirst sheet 36 may be cured in order to provide a permanent, rigid,textured surface 44 on the first sheet 36. In still another step 56 ofthe method 10, the three-dimension textured surface 44 may be heated andpressed against an initially flat Tedlar release sheet 58 adhered to aninitially flat uncured epoxy impregnated fiberglass sheet 60 to changethe release sheet 58 and the fiberglass sheet 60 to the texturedconfiguration 62 shown in FIG. 8. FIG. 8 is a side-view of the texturedsurface 44 of the first sheet 36 of FIG. 7 being heated and pressedagainst the Tedlar release sheet 58 adhered to the uncured epoxyimpregnated fiberglass sheet 60 to change the initially flat releasesheet 58 and the initially flat fiberglass sheet 60 to the texturedconfiguration 62. In other embodiments, the release sheet 58 and sheet60 may be formed of varying materials.

In step 64 of the method 10, as shown in FIG. 8, the fiberglass sheet 60may be cured to form a cured fiberglass composite blanket 64 having anegative three-dimensional textured surface 66 which is the inverseimage 68 of the three-dimensional textured surface 44 printed on thefirst sheet 36. During step 70 of the method 10, as shown in FIG. 9, thenegative three-dimensional textured surface 66 of the cured fiberglasscomposite blanket 64 may be heated and pressed into a decorativelaminate 72 to form a three-dimensional textured surface 74 on thedecorative laminate 72. The three-dimensional textured surface 74 on thedecorative laminate 72 may be substantially identical to both thethree-dimensional textured surface 44 on the first sheet 36 as shown inFIG. 7 and to the digital image 26 of the target texture 14 as shown inFIG. 4. The decorative laminate 72 may comprise a part of an aircraft75, such as a decorative interior wall, ceiling, stowage bin, or otherdecorative portion of an aircraft. In other embodiments, the method 10may be used to form any type of aircraft part. The composite blanket 64may be used multiple times to make multiple decorative laminates 72.

In another embodiment, a thermally stable first sheet 36 may be providedhaving a three-dimensional textured surface 44 on the first sheet 36, asshown in FIG. 7. The three-dimensional textured surface 44 may have beenformed by printing a pattern 40 of material 42 on the first sheet 36 andcuring the material 42. The material 42 may comprise Ultra Violet Curedink and the first sheet 36 may comprise a film 37 made of Mylar orPolyester. A target texture 14 may have been identified or designedprior to forming the three-dimensional textured surface 44 on the firstsheet 36. A digital image 26 of the target texture 14 may have beenformed on a computer 28 by scanning the target texture 14 into thecomputer 28 or using a computer program 32 to prepare the digital image26. Multiple layers 43 may have been printed on the first sheet 36 toform the three-dimensional textured surface 44 on the first sheet 36.

The first sheet 36 may be for heating and pressing the three-dimensionaltextured surface 44 against a release sheet 58 adhered to an uncuredepoxy impregnated fiberglass sheet 60 in order to form a compositeblanket 64 having a negative three-dimensional textured surface 66 whichis the inverse image 68 of the three-dimensional textured surface 44 onthe first sheet 36. The composite blanket 64 may be for heating andpressing the negative three-dimensional textured surface 66 of thecomposite blanket 64 into a decorative laminate 72 to form athree-dimensional textured surface 74 on the decorative laminate 72which is substantially identical to the three-dimensional texturedsurface 44 on the first sheet 36. The decorative laminate 72 may be apart of an aircraft.

One or more embodiments of the disclosure may allow for the productionof decorative laminates 72 using a process which is more efficient, lesstimely, less time-consuming, less complex, allows for more varied typesof decorative laminates 72 to be produced, and/or provides one or moreother types of improvements over one or more of the existing methods.For instance, the tooling of the disclosure may comprise inexpensivefilm and cured ink, and the production process may take only hours asopposed to months under one or more of the existing methods.

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 180 as shown in FIG. 10 and an aircraft 181 as shownin FIG. 11. During pre-production, exemplary method 180 may includespecification and design 182 of the aircraft 181 and materialprocurement 183. During production, component and subassemblymanufacturing 184 and system integration 185 of the aircraft 181 takesplace. Thereafter, the aircraft 181 may go through certification anddelivery 186 in order to be placed in service 187. While in service by acustomer, the aircraft 181 is scheduled for routine maintenance andservice 188 (which may also include modification, reconfiguration,refurbishment, and so on).

Each of the processes of method 180 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof venders, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 11, the aircraft 181 produced by the exemplary method180 may include an airframe 189 with a plurality of systems 190 and aninterior 191. Examples of high-level systems 190 include one or more ofa propulsion system 192, an electrical system 193, a hydraulic system194, and an environmental system 195. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of theinvention may be applied to other industries, such as the automotiveindustry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 180. Forexample, components or subassemblies corresponding to production process184 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 181 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 184 and 185, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 181. Similarly, one or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized while the aircraft181 is in service, for example and without limitation, to maintenanceand service 188.

It should be understood, of course, that the foregoing relates toexemplary embodiments of the disclosure and that modifications may bemade without departing from the spirit and scope of the disclosure asset forth in the following claims.

1-21. (canceled)
 22. A thermally stable first sheet having athree-dimensional textured surface on the first sheet, wherein thethree-dimensional textured surface was formed by printing a pattern ofmaterial on the first sheet and curing the material.
 23. The first sheetof claim 22, wherein the material is Ultra Violet Cured ink.
 24. Thefirst sheet of claim 22, wherein the first sheet is a film.
 25. Thefirst sheet of claim 24, wherein the first sheet is made of at least oneof Mylar and Polyester.
 26. The first sheet of claim 22, wherein atarget texture was at least one of identified and designed prior toforming the three-dimensional textured surface on the first sheet. 27.The first sheet of claim 26, wherein a digital image of the targettexture was formed on a computer.
 28. The first sheet of claim 27,wherein the digital image was formed on the computer by at least one ofscanning the target texture into the computer and using a computerprogram to prepare the digital image.
 29. The first sheet of claim 22,wherein multiple layers were printed on the first sheet to form thethree-dimensional textured surface on the first sheet.
 30. The firstsheet of claim 22, wherein the first sheet is for heating and pressingthe three-dimension textured surface against a release sheet adhered toan uncured epoxy impregnated fiberglass sheet in order to form acomposite blanket having a negative three-dimensional textured surfacewhich is the inverse image of the three-dimensional textured surface onthe first sheet.
 31. The first sheet of claim 30, wherein the compositeblanket is for heating and pressing the negative three-dimensionaltextured surface of the composite blanket into a decorative laminate toform a three-dimensional textured surface on the decorative laminatewhich is substantially identical to the three-dimensional texturedsurface on the first sheet.
 32. The first sheet of claim 31, wherein thedecorative laminate is a part of an aircraft.